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Author Topic: ‘78 CB550 Cafe Racer Project  (Read 14375 times)

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Offline jcop550

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‘78 CB550 Cafe Racer Project
« on: February 09, 2019, 10:15:42 PM »
I have had this 1978 Honda cb550 for a few years now. My plan was always to do a cafe racer build with it. I had this thing put together and taken apart a couple times over the years. It has always been a work in progress that I would lose interest in. Now I finally got the motivation to finish this project and I couldn’t be more excited to do so. I’ll post some pictures I collected along the way and then I’ll continue to update you all with the build as it progresses!

« Last Edit: February 10, 2019, 12:58:12 PM by jcop550 »
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Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #1 on: February 10, 2019, 12:10:41 PM »
This is where I’m at with the project right now. Completely taken down to the frame. Currently prepping the frame and engine for paint!


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Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #2 on: February 10, 2019, 04:58:50 PM »
Started to wet sand and try out this polishing kit I bought. I forgot how tedious wet sanding was. Some before and after pics


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Offline jcop550

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‘78 CB550 Cafe Racer Project
« Reply #3 on: February 11, 2019, 09:01:56 PM »
I got a set of used super sport 4 into 1 headers and got a cone muffler to weld on to them with the help of my brother’s friend

The headers are in ok condition. Some surface rust, and a little bit of pitting but nothing too bad. I’m gonna try and get them cleaned up as much as possible but I think I’m going to end up wrapping them with black heat wrap

12” Shorty Cone Muffler: https://www.dimecitycycles.com/stainless-steel-shorty-universal-cone-muffler-fitting-1-1-4-inch-exhausts.html

« Last Edit: February 11, 2019, 09:08:11 PM by jcop550 »
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Offline rocs

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Re: ‘78 CB550 Cafe Racer Project
« Reply #4 on: February 12, 2019, 05:14:02 AM »
Subscribed!

Looking good! Polishing looks great as well. I dont miss those days at all.

Also, saw your wanted add for a custom top triple clamp. I dont have one myself but hoping someone can help you out.
« Last Edit: February 12, 2019, 05:15:41 AM by rocs »
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1975 CB550k's

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #5 on: February 12, 2019, 06:47:59 AM »
Quote from: rocs on February 12, 2019, 05:14:02 AM
Subscribed!

Looking good! Polishing looks great as well. I dont miss those days at all.

Also, saw your wanted add for a custom top triple clamp. I dont have one myself but hoping someone can help you out.
Awesome, thanks brother! You do great work


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Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #6 on: February 12, 2019, 05:22:01 PM »
I started to strip all of the old paint off the frame down to bare metal this evening.

Got about half way through because I need a new wire wheel after this ones wire bristles broke off. So far I’m happy with the progress!!


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Offline calj737

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Re: ‘78 CB550 Cafe Racer Project
« Reply #7 on: February 13, 2019, 03:11:58 AM »
Chemical paint stripper is faster, safer, and easier on your body than those wires flying off and sticking in your skin, eyes, and surrounds. Follow the stripper up with some 400 grit emery or a Red ScotchBrite.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #8 on: February 13, 2019, 04:51:42 AM »
Quote from: calj737 on February 13, 2019, 03:11:58 AM
Chemical paint stripper is faster, safer, and easier on your body than those wires flying off and sticking in your skin, eyes, and surrounds. Follow the stripper up with some 400 grit emery or a Red ScotchBrite.
Yeah I’m sure. I was picking those wires out of my shirt and off the floor for a while. They were everywhere. It took the paint off with ease though


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Offline calj737

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Re: ‘78 CB550 Cafe Racer Project
« Reply #9 on: February 13, 2019, 05:02:41 AM »
Make damn skippy certain you wear eye protection.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #10 on: February 13, 2019, 05:08:56 AM »
Quote from: calj737 on February 13, 2019, 05:02:41 AM
Make damn skippy certain you wear eye protection.
Yeah of course! I’d like to keep my vision lol. And a respirator for the paint dust as well


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Offline SOHC4 Cafe Racer Fan

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Re: ‘78 CB550 Cafe Racer Project
« Reply #11 on: February 13, 2019, 08:33:15 AM »
What Cal said.  Get yourself a stripper!  ;)  Unless you are going to clear over bare metal, use a chemical stripper.  Remember to wipe down the frame 2-3 times with acetone before applying primer/paint.
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #12 on: February 13, 2019, 09:07:08 AM »
Lol thanks! I will definitely wipe it down. For now I got a stronger wire wheel and it is working like magic. Takes the paint off like butter.

Here’s a pic of my new one and what happened to the other one. So far no wire bristles flying off



I’ll add some photos of the frame when get all the paint off!


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Offline calj737

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Re: ‘78 CB550 Cafe Racer Project
« Reply #13 on: February 13, 2019, 09:12:16 AM »
Loose knot on the left, tight knot on the right. Both sling badly. Nature of the coils. Left is easier on the metal. Right is easier in notches. Both demand eyewear.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #14 on: February 13, 2019, 10:51:24 AM »
Well here is the frame after removing all the paint. Took a little less than 2 hours all together with the wire wheel. Done with that for now. Then primer and paint once it gets warmer outside


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Offline Kelly E

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Re: ‘78 CB550 Cafe Racer Project
« Reply #15 on: February 13, 2019, 11:07:37 AM »
That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.
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Never Give Up - Never Surrender

The Rust Bros. Garage Collection
1974 Honda CB 550 K0                                            1971 MGB/GT
1975 Honda CB 400F Super Sport                          1972 MGB/GT
1977 Kawasaki KZ 1000 LTD                                   1985 GMC S15
1978 Kawasaki KL 250
1980 Suzuki GS 1100E
1982 Honda CB 900F Super Sport
1983 Honda CB 1100F
1984 Honda VF 700S Sabre
1984 Honda VF 1000F Interceptor
1990 Moto Guzzi 1000 Le Mans
1994 Kawasaki Concours ZG 1000A9
2005 Harley Davidson Fat Boy

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #16 on: February 13, 2019, 11:41:45 AM »
Quote from: Kelly E on February 13, 2019, 11:07:37 AM
That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.
Thank you! I wish I had a sandblaster but I’m stuck doing it the old fashioned way.


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Offline Bankerdanny

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Re: ‘78 CB550 Cafe Racer Project
« Reply #17 on: February 13, 2019, 01:05:12 PM »
Quote from: Kelly E on February 13, 2019, 11:07:37 AM
That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.

I spot blasted the frame on my 550 roller rather than doing the whole thing.
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"The problem with quotes on the Internet is that you never know if they're true" - Abraham Lincoln

Current: '76 CB750F. Previous:  '75 CB550F, 2007 Yamaha Vino 125 Scooter, '75 Harley FXE Superglide, '77 GL1000, '77 CB550k, '68 Suzuki K10 80, '68 Yamaha YR2, '69 BMW R69S, '71 Honda SL175, '02 Royal Enfield Bullet 500, '89 Yamaha FJ1200

Offline Kelly E

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Re: ‘78 CB550 Cafe Racer Project
« Reply #18 on: February 13, 2019, 02:52:12 PM »
I am going to blast the 550 as well, most likely this summer after my ride in July.
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Never Give Up - Never Surrender

The Rust Bros. Garage Collection
1974 Honda CB 550 K0                                            1971 MGB/GT
1975 Honda CB 400F Super Sport                          1972 MGB/GT
1977 Kawasaki KZ 1000 LTD                                   1985 GMC S15
1978 Kawasaki KL 250
1980 Suzuki GS 1100E
1982 Honda CB 900F Super Sport
1983 Honda CB 1100F
1984 Honda VF 700S Sabre
1984 Honda VF 1000F Interceptor
1990 Moto Guzzi 1000 Le Mans
1994 Kawasaki Concours ZG 1000A9
2005 Harley Davidson Fat Boy

Offline jcop550

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‘78 CB550 Cafe Racer Project
« Reply #19 on: February 14, 2019, 07:01:18 PM »
Here’s an idea of what I’m going for with the seat and tank. I got a bit of work to do on the tank and I think I’m gonna keep it white. I think the white looks good with the saddle brown seat!

Also gonna have gold accents like the chain and emblems etc.

Let me know what you guys think!




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« Last Edit: February 14, 2019, 07:29:34 PM by jcop550 »
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Offline calj737

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Re: ‘78 CB550 Cafe Racer Project
« Reply #20 on: February 15, 2019, 03:20:24 AM »
Easiest “work in the tank” to make it fit is to move the frame bungs that the tank hangs on. Simply cut them off, and scoot them forward, up or down, and then weld them back on. Done. Then you don’t mess with the tank, your seat fits, and it’s less than a 1 hour job.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #21 on: February 15, 2019, 04:54:11 AM »
Quote from: calj737 on February 15, 2019, 03:20:24 AM
Easiest “work in the tank” to make it fit is to move the frame bungs that the tank hangs on. Simply cut them off, and scoot them forward, up or down, and then weld them back on. Done. Then you don’t mess with the tank, your seat fits, and it’s less than a 1 hour job.
Yes, I had the tank and seat on before I took apart the bike. Everything actually fits nicely. I guess you can say I got lucky lol


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Offline Bankerdanny

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Re: ‘78 CB550 Cafe Racer Project
« Reply #22 on: February 15, 2019, 10:37:54 AM »
I have that same basic seat and used it on my own 550F for a while. On a stock bike the fit is so-so because of the frame brace for the top of the fender, but with the frame behind the shock mounts removed and a hoop added like your bike I imaging the fit should be very good.
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"The problem with quotes on the Internet is that you never know if they're true" - Abraham Lincoln

Current: '76 CB750F. Previous:  '75 CB550F, 2007 Yamaha Vino 125 Scooter, '75 Harley FXE Superglide, '77 GL1000, '77 CB550k, '68 Suzuki K10 80, '68 Yamaha YR2, '69 BMW R69S, '71 Honda SL175, '02 Royal Enfield Bullet 500, '89 Yamaha FJ1200

Offline jcop550

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Re: ‘78 CB550 Cafe Racer Project
« Reply #23 on: February 15, 2019, 11:57:10 AM »
Quote from: Bankerdanny on February 15, 2019, 10:37:54 AM
I have that same basic seat and used it on my own 550F for a while. On a stock bike the fit is so-so because of the frame brace for the top of the fender, but with the frame behind the shock mounts removed and a hoop added like your bike I imaging the fit should be very good.
Oh very interesting. I didn’t know this seat would fit on the bike before the frame got chopped. Pretty cool. But yes, with the hoop welded on the back the seat fits very nicely.


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Offline Bankerdanny

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Re: ‘78 CB550 Cafe Racer Project
« Reply #24 on: February 15, 2019, 07:06:35 PM »
Quote from: jcop550 on February 15, 2019, 11:57:10 AM
Oh very interesting. I didn’t know this seat would fit on the bike before the frame got chopped. Pretty cool. But yes, with the hoop welded on the back the seat fits very nicely.

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« Last Edit: February 15, 2019, 07:08:53 PM by Bankerdanny »
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"The problem with quotes on the Internet is that you never know if they're true" - Abraham Lincoln

Current: '76 CB750F. Previous:  '75 CB550F, 2007 Yamaha Vino 125 Scooter, '75 Harley FXE Superglide, '77 GL1000, '77 CB550k, '68 Suzuki K10 80, '68 Yamaha YR2, '69 BMW R69S, '71 Honda SL175, '02 Royal Enfield Bullet 500, '89 Yamaha FJ1200
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